Relay construction



Aug.- 1-8, 1970 R. L. M-ART|N RELAY CONSTRUCTION 4 Sheets-Sheet 1 Filed Aug. 29, 1968 INVENTOR. Rose/er L MART/As Aug.- 18, 1970 R. L. MARTIN RELAY CONSTRUCTION Filed Aug. 29, 1968 4 Sheetsheec. 23

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Aug. 18, 1970 R. L. MARTIN 3,525,051

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fiedlwa m r flrroede YS United States Patent 3,525,061 RELAY CONSTRUCTION Robert L. Martin, Thousand Oaks, Calif., assignor to Charles E. Gutentag, Los Angeles, Calif., a corporation Continuation-in-part of application Ser. No. 634,144,

Apr. 27, 1967. This application Aug. 29, 1968, Ser.

Int. Cl. H0lh 51/06 US. Cl. 335203 13 Claims ABSTRACT OF THE DISCLOSURE A relay device usually of miniature proportions in which a core around which wire is wound to form a coil is of non-magnetic metal and attached metal to metal to plate pieces at opposite ends and over which extends a magnetic sleeve. Two armature bars are pivotally mounted in the core and provided at one end of each with a movable contact spring urged in one direction with respect to fixed contacts in a recess formed in a dielectric mount on the outside of the magnetic plate piece. When the two armature bars are to move simultaneously, the spring urging one bar is made intentionally slightly weaker than the spring urging the other bar and a pick-up element on the bar with the weaker spring which moves first then engages the other bar so that before movement is complete both bars are moving precisely simultaneously.

This case is a continuation-in-part of application Ser. No. 634,144 filed Apr. 27, 1967.

The progressively increasing demand for more compact electronic equipment, whether airborne or confined in spaces such, for example, as a computer has promoted the evolution of micro-miniature technology requiring that electric devices be made smaller and smaller. When such devices are so small that they must be constructed under a microscope, space becomes very much a premium and although a new design may make possible a space saving operation of only a few thousandths of an inch, such space saving becomes extremely important when it is a large overall percentage of the size of the device itself. In view of this, the selection of materials is important in that, for example, if a part can be made of metal, it can be many times smaller than a part made of one of the cemmercial plastics, the difliculty residing in the fact that not all desirable metals are non-magnetic and virtually none are dielectric.

Moreover, because electric relays need to have movable parts, the construction of them in micro-miniature proportions becomes an appreciable problem, both from the point of view of initial construction, the point of view of maintenance, a desirable life span, and a necessary degree of precision as when working with tolerances which need to be measured in a few thousandths of an inch or less.

Among the objects of the invention is to provide a new and improved relay construction capable of being built in micro-miniature size wherein the inherent construction is such as to devote substantially a maximum amount of space to portions of the device which generate magnetic energy.

Another object of the invention is to provide a new and improved relay device capable of being built in micro miniature size which has substantially greater power than relays of comparable overall dimension heretofore constructed.

Still another object of the invention is to provide a new and improved relay device capable of being built in micro-miniature size which is assembled in a precise relationship of parts and with spacings built into the assembly, thereby to assure precise performance and to make adjustment unnecessary.

Still another object of the invention is to provide a new and improved relay device capable of being built in micro-miniature size which is versatile in character in the assembly of a plurality of armatures movable either simultaneously or in alternately opposite directions but which in either event is so constructed that the device is precision built when assembled whereby to obviate need for subsequent adjustment.

With these and other objects in view, the invention consists in the construction, arrangement and combination of the various parts of the device, whereby the objects contemplated are attained, as hereinafter set forth, pointed out in the appended claims, and illustrated in the accompanying drawings.

In the drawings:

FIG. 1 is an exploded perspective view showing the parts of one form of the device in disassembled condition.

FIG. 2 is an exploded perspective view of parts of the device in subassembled form.

FIG. 3 is a longitudinal sectional view of the device looking in one direction.

FIG. 4 is a longitudinal sectional view of the device looking in a direction degrees removed from FIG. 3.

FIG. 5 is a cross-sectional view on the line 5-5 of FIG. 3.

FIG. 6 is an exploded perspective view of parts of a second form of the device in assembled condition.

FIG. 7 is a side perspective view of the device of FIG. 6 partially broken away.

FIG. 8 is an end elevational view of the devices of FIG. 7.

FIG. 9 is a schematic view of armature mounting of the devices of FIGS. 6, 7 and 8 from the relay side of the header with coil energized.

In an embodiment of the invention chosen for the purpose of illustration there is shown one form of relay in FIGS. 1 through 5, inclusive, which features two armature bars carrying movable contacts pivotally mounted on a common axis of rotation within the core of a coil form and adapted to move simultaneously in the same direction. The armature bars are identified by the reference characters 10 and 11 which are mounted on a pivot shaft 12 in turn extending into holes 13 in a tubular core 14 so that the armature bars are contained within a passage 15 through the core 14. It is significant that the core 14 is a metal core constructed of a metal having nonmagnetic properties such, for example, as stainless steel, brass, or bronze. Other metals having relatively high strength in light gauge construction 'but non-magnetic in character may also be appropriate.

At opposite ends of the core 14 are respective magnetic plate pieces 16 and 17, these being identical in form in the embodiment described but oriented in opposite directions at opposite ends of the core '14. Extending over the core 14 is a passage 18 on one side of which is a magnetic abutting shoulder 19.

The other plate piece 17 is similarly provided with a passage 21 having a magnetic abutting shoulder 22 on one side and a slot 23. The slot 23 provides for the passage of wire leads.

The plate pieces 16 and 17 are assembled on the core 14 at the locations shown in FIGS. 3 and 4, namely, at opposite ends, there being a metal to metal attachment between the core and pole pieces made, for example, 'by welding, brazing or other conventional technique. When so assembled, the passages 18 and 21 are in axial alignment with the armature bars 10 and 11. After this assembly has been completed, the exterior surface of the core 14 and adjacent faces of the plate pieces 16 and 17 are coated with a coating 25 of electrically insulating character. The space between the plate pieces is then filled with wire wound around the exterior of the core to form a coil 26, and the coil provided with a conventional exterior protective film 27.

Adjacent the exterior of the lower plate piece 17, as viewed in FIGS. 1, 3 and 4, there is attached a mount 28 in the form of a disc of dielectric material in which sundry contacts are embedded, the mount being attached to the exterior of the plate piece 17 by some appropriate adhesive. Centrally disposed in the mount 28 is a recess 29, in alignment with the passages 15, 18 and 21 and the armature bars and 11. Projections 30 may be provided to assist in centering the mount '28 with respect to the plate piece 17. A disc 31 forms the bottom end of the structure with a flanged surface 32 which forms a means by which a housing 33 can be mounted to seal an interior chamber 34 which contains substantially all of the relay device. Before attachment of the housing at the location described there is a magnetic sleeve 35 applied over the plate pieces 16 and 17 and the coil 26, thereby confining the coil entirely within the sleeve, the sleeve completing the magnetic path between the plate pieces 16 and 17.

In the mount 28 and within the recess 29 there are provided two sets of fixed contacts, one set consisting of individual contacts 36 and 37 on one side and the other set consisting of individual contacts 38 and 39 on the opposite side. Contact pins are mounted in the disc 31, insulated one from another, and in the embodiment shown pins 40 and 41 are respectively connected to individual contacts 38 and 36 while pins 42 and 43 are respectively connected to individual contacts 39 and 37. Leads from the coil 26 (but not shown in the interest of clarity) connect to respective pins 44 and 45. Pins 46 and 47 provide contacts for respective flexible leads or pigtails 48 and 49 best shown in FIG. 1 and routed in the space provided between mount 28 and disc 31. The flexible lead 48 attaches to a movable contact 50 on the lower end of the armature bar 10 to which it is attached by an insulating adhesive. Similarly, the flexible lead 49 is attached to a movable contact 51 on the armature bar 11 to which its is secured with a similar insulating adhesive.

T o bias the armature bar 10 normally into contact with the fixed contact 36, making it a normally closed contact, there is provided an L-shaped spring 55, a lower leg 56 of which is attached to the armature bar 10 at a location below the pivot shaft 12, as shown in FIG. 4. An upper leg 57 extends over the plate piece 16 to which it is attached by a weldment 58.

Similarly, an L-shaped spring 59 has a lower leg 60 attached to the armature bar 11, as shown in FIGS. 3 and 4, and an upper leg 61 extending over and attached to the plate piece 16 by means of a weldment 62.

To further assure simultaneous movement of the armature bars 10 and 11 there is a small wire rod 65 welded to armature bar 10 adjacent the upper end of the bar, as viewed in FIGS. 1, 3 and 4, the wire rod extending laterally to overlie the armature bar 11. In this relationship of parts the L-shaped spring 55 is made slightly weaker than the L-shaped spring 59 so that it will yield first, momentarily in advance of yielding of the spring 59 when the coil is energized, in which event the wire rod 65 will be pulled against the armature bar 11 as soon as the armature bar 10 begins to move and thereafter both armature bars will move precisely simultaneously as they shift from normally closed positions against fixed contacts 36 and 37 to closed positions against normally open fixed contacts 38 and 39.

After the device has been assembled in the form shown in FIGS. 3 and 4, the air in the chamber 34 may be exhausted through a tube 66, leaving the operating parts hermetically sealed by reason of the impervious disc 31 being sealed around its perimeter with an adjacent portion of the housing 33. In the alternative, an appropriate 4 gas may be injected into the chamber 36 through the same tube 66.

In operation it may be assumed that the movable contacts 50 and 51 are normally urged by spring pressure against fixed contacts 36 and 37. When the coil 26 is then energized, there is a magnetic circuit created in the plate pieces 16 and 17 passing through the magnetic sleeve 35 whereupon the respective ends of the armature bars 10 and 11 are drawn against appropriate abutting shoulders 19 and 22, causing the movable contacts 50 and 51 to move away from the fixed contacts 36 and 37 into engagement with the other fixed contacts 38 and 39. When the circuit through the coil 26 is opened, the magnetic field collapses releasing the armature bars and the springs return them to their original position.

In a second form of the invention illustrated in FIGS. 6, 7, 8, and 9 the device is horizontally mounted upon a base plate 70. As in the first described form, there is a core 71 of an appropriate non-magnetic metal having a passage 72 therethrough, opposite ends of the core being secured in metal to metal engagement with appropriate magnetic plate pieces 73 and 74. In the plate piece 73 is a passage 75 providing a magnetic abutting shoulder 78. Here again the exterior surface of the core 71 and adjacent faces of the plate pieces 73 and 74 are coated with an appropriate insulated film 79. Wire wound around the core 71 forms a coil 80. Extending over the coil 80 is a magnetic sleeve 81, the magnetic sleeve being in engagement with respective plate pieces 73 and 74 at the opposite ends of the core 71.

Within the passage 72 in the core are armature bars 82 and 83 carried by a pivot shaft 84 which extends into holes 85 in the core 71, thereby pivotally supporting the bars 82 and 83 in the core. At the left end of the armature bar 82, as viewed in FIG. 6, is a movable contact 86 attached to the bar by an insulating adhesive 87. Similarly, on the armature bar 83 is a movable contact 88 attached thereto by an insulating adhesive 89. An L-shaped spring 90 has one leg 91 connected to the armature bar 82 at a location toward the left of the pivot shaft 84 and a leg 92 which overlies the plate piece 73 and is attached thereto by an appropriate weldment 93. Similarly, an L-shaped spring 94 has one leg attached to the right-hand end of the armature bar 83 at a location not visible in FIG. 6 but on the right of the pivot shaft 84 and a leg 96 which is adapted to overlie the plate piece 74 for attachment thereto by welding in the same manner as leg 92 of the spring 90.

In this form of the device an insulating mount 100 has a recess 101 therein into which the movable contact 88 extends so as to be capable of engagement with a fixed contact 102 on one side and a similar fixed contact 103 on the other side. At the other end is a mount 104 in which is a recess 105 providing two fixed contacts 106 and 107.

Fixed contacts 102 and 103 are connected, respectively, to contact pins 108 and 109 insulated from base plate 70 and fixed contacts 106 and 107 are connected to respective pin contacts 110 and 111, also insulated from base plate 70. A flexible lead or pigtail 112 from the movable contact 86 is connected to a pin contact 113 and a similar flexible lead or pigtail 114 from the movable contact 88 is connected to a pin contact 115. Pin contacts 116 and 117 are for the accommodation of leads from the coil 80 in a conventional connecting arrangement.

When the device is assembled, a housing 118 providing a chamber 119 is applied over all of the parts and attached around its lower perimeter, as viewed in FIGS. 7 and 8, to form a seal 120, thereby to make it possible to hermetically seal the chamber 119.

In operation of this form of the device it can be assumed that, as for example in FIG. 9, the movable contact 86 is spring pressed to closed position against the fixed contact 107 and the movable contact 88 is spring pressed to closed position against the fixed contact 102. When the coil 80 is energized, a magnetic field is set up and the movable contact 86 is swung into contact with the fixed contact 106. At the same time the movable contact 88 is swung to a position of engagement with the fixed contact 103. Following this, when the coil is de-energized, the magnetic field collapses and the springs move the movable contacts back to their original positions.

While the invention has herein been shown and described in what is conceived to be a practical and eifective embodiment, it is recognized that departures may be made therefrom within the scope of the invention, which is not to be limited to the details disclosed herein but is to be accorded the full scope of the claims so as to embrace any and all equivalent devices.

Having described the invention, what is claimed as new in support of Letters Patent is:

1. An electromagnetic relay comprising a hollow tubular core element of metallic non-magnetic material, transversely extending magnetic plate pieces mounted at opposite ends of the core in metal to metal engagement therewith, and a coil winding around said core and between said plate pieces, said plate pieces each having a passage therethrough forming a magnetic abutting shoulder on one side, a mount of dielectric material on the outer face of each plate piece and having a recess therein in alignment with said respective passage, an electric contact element in the recess, and a plurality of electric contact members in said mount, one of said members being in contact with said contact element, a plurality of armature bars having movable electric contacts at ends thereof and a flexible electric connection from each movable contact to one of said contact members, a pivot shaft extending from the wall of said core into a mounting engagement with said bars intermediate opposite ends thereof and resilient means normally biasing said bars to positions tilted away from said magnetic abutting shoulders to a position where one electric condition prevails in said movable contacts, said coil when energized being productive of magnetic attraction between said bars and said magnetic abutting shoulders exceeding in force the resisting force of said resilient means, said bars being moved toward said shoulders to a position where another electric condition prevails in said movable contacts.

2. An electromagnetic relay as in claim 1 wherein there are two bars in side by side parallel relationship movable simultaneously in the same direction.

3. An electromagnetic relay as in claim 1 wherein there are two bars in side by side parallel relationship movable simultaneously in opposite directions.

4. An electromagnetic relay as in claim 2 wherein the movable contacts are at adjacent ends of the bars.

5. An electromagnetic relay as in claim 2 wherein the movable contacts are at opposite ends of the bars.

6. An electromagnetic relay as in claim 1 wherein there is a magnetic sleeve extending over the coil wind ing from one magnetic plate piece to the other magnetic plate piece.

7. An electromagnetic relay as in claim 1 wherein there are two sets of fixed contacts in each recess, one set being on the side adjacent said magnetic abutting shoulder and the other set being on the side opposite therefrom, said contact means comprising outwardly projecting pins and electric leads from said pins to said fixed contacts.

8. An electromagnetic relay as in claim 1 wherein said resilient means comprises a bent wire spring for each bar, one arm of said spring being fastened to the bar on one side of the pivot shaft and the other end of said spring being in engagement with a magnetic plate piece.

9. An electromagnetic relay as in claim 2 wherein the movable contacts are at adjacent ends of the bars, the resilient means for one of said bars being weaker than the resilient means for the other bar, and a pick-up element on said one bar extending into engagement with the other bar whereby both bars are moved simultaneously into position against said fixed contacts.

10. An electromagnetic relay as in claim 1 wherein the exterior of said core and the inside faces of said magnetic plate pieces are coated with a relatively thin layer of dielectric film.

11. An electromagnetic relay as in claim 3 wherein the movable contacts are at adjacent ends of the bars.

12. An electromagnetic relay as in claim 3 wherein the movable contacts are at opposite ends of the bars.

13. An electromagnetic relay as in claim 3 wherein the movable contacts are at adjacent ends of the bars, the resilient means for one of said bars being weaker than the resilient means for the other bar, and a pick-up element on said one bar extending into engagement with the other bar whereby both bars are moved simultaneous- 1y into position against said fixed contacts.

References Cited UNITED STATES PATENTS 3,202,782. 8/1965 Mathison 335-203 BERNARD A. GILHEANY, Primary Examiner H. BROOME, Assistant Examiner 

